System and method for weld path generation

ABSTRACT

Embodiments of the present disclosure are directed towards a robotic system and method. The system may include a robot and a three dimensional sensor device associated with the robot configured to scan a welding area and generate a scanned welding area. The system may include a processor configured to receive the scanned welding area and to generate a three dimensional point cloud based upon, at least in part the scanned welding area. The processor may be further configured to perform processing on the three dimensional point cloud in a two-dimensional domain. The processor may be further configured to generate one or more three dimensional welding paths and to simulate the one or more three dimensional welding paths.

TECHNICAL FIELD

The invention generally relates to robotics and more specifically to asystem and method for generating a weld path.

BACKGROUND

Robots and robotic systems are being used in more and more industrialapplications. For example, robots have been used to assist in numerouswelding tasks. These types of systems generally require a computer aideddesign (“CAD”) model in order to generate the most accurate andefficient welding path. These existing systems are also directed towardsscanning a particular area of a part and do not scan the entire possiblewelding area.

SUMMARY

In one or more embodiments of the present disclosure, a system isprovided. The system may include a robot and one or more threedimensional sensor devices associated with the robot configured to scana welding area and generate a scanned welding area. The system mayfurther include one or more processors configured to receive the scannedwelding area and to generate a three dimensional point cloud based upon,at least in part the scanned welding area, the one or more processorsfurther configured to perform processing on the three dimensional pointcloud in a two-dimensional domain, the one or more processors furtherconfigured to generate one or more three dimensional welding paths andto simulate the one or more three dimensional welding paths.

One or more of the following features may be included. Processing thethree-dimensional point cloud in a two-dimensional domain may include atleast one of binary image thinning of a welding path or smoothing awelding path based upon, at least in part, a moving average filter.Processing the three-dimensional point cloud in a two-dimensional domainmay also include analysis of one or more environmental or robotconstraints. Simulating the one or more three dimensional welding pathsmay include verifying feasibility of the one or more three dimensionalwelding paths. If the one or more three dimensional welding paths arenot verified, the one or more processors may be further configured tore-simulate after altering a position of a welding table or a weldingpart. Performing processing on the three dimensional point cloud in atwo-dimensional domain may include converting the three dimensionalpoint cloud to a height field. Performing processing on the threedimensional point cloud in a two-dimensional domain may include applyinga local minimum filter to the height field. Binary image thinning mayinclude removing one or more branch nodes, wherein a branch nodecorresponds to a pixel having more than two neighbors. The system mayfurther include a graphical user interface configured to allow a user toselect a filter size, select a point cloud for processing, visualize aweld path result or save the one or more three-dimensional weldingpaths. The system may use one or more processors to maintain a weldingformation with respect to gravity as a welding process is beingperformed. Maintaining the welding formation may be based upon, at leastin part, one or more extra degrees of freedom associated with the robot.

In another embodiment of the present disclosure, a method is provided.The method may include providing a robot and scanning a welding areausing one or more three dimensional sensor devices associated with therobot to generate a scanned welding area. The method may further includereceiving the scanned welding area at one or more processors andgenerating a three dimensional point cloud based upon, at least in partthe scanned welding area. The method may also include processing thethree dimensional point cloud in a two-dimensional domain to generateone or more three dimensional welding paths and simulating the one ormore three dimensional welding paths.

One or more of the following features may be included. Processing thethree-dimensional point cloud in a two-dimensional domain may include atleast one of binary image thinning of a welding path or smoothing awelding path based upon, at least in part, a moving average filter.Processing the three-dimensional point cloud in a two-dimensional domainmay also include analysis of one or more environmental or robotconstraints. Simulating the one or more three dimensional welding pathsmay include verifying feasibility of the one or more three dimensionalwelding paths. If the one or more three dimensional welding paths arenot verified, the one or more processors may be further configured tore-simulate after altering a position of a welding table or a weldingpart. Performing processing on the three dimensional point cloud in atwo-dimensional domain may include converting the three dimensionalpoint cloud to a height field. Performing processing on the threedimensional point cloud in a two-dimensional domain may include applyinga local minimum filter to the height field. Binary image thinning mayinclude removing one or more branch nodes, wherein a branch nodecorresponds to a pixel having more than two neighbors. The method mayallow a user to select a filter size, select a point cloud forprocessing, visualize a weld path result or save the one or morethree-dimensional welding paths. The method may include using one ormore processors to maintain a welding formation with respect to gravityas a welding process is being performed wherein maintaining the weldingformation is based upon, at least in part, one or more extra degrees offreedom associated with the robot.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the nature and objects of the presentdisclosure, reference is made to the following detailed descriptiontaken in conjunction with the following drawings, in which:

FIG. 1 is a block diagram of a weld path generation robotic system,according to an embodiment of the present disclosure;

FIG. 2 is a graphical user interface showing multiple degrees of freedomof a weld path generation robotic system, according to an embodiment ofthe present disclosure;

FIG. 3 is a flowchart of a weld path generation robotic method,according to an embodiment of the present disclosure;

FIG. 4 is another flowchart of a weld path generation robotic method,according to an embodiment of the present disclosure;

FIG. 5 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 6 is a scanner for use with a weld path generation robotic method,according to an embodiment of the present disclosure;

FIG. 7 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 8 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 9 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 10 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 11 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 12 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 13 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 14 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure;

FIG. 15 is a diagram showing aspects of a weld path generation roboticmethod, according to an embodiment of the present disclosure; and

FIG. 16 is a graphical user interface of a weld path generation system,according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the subject application may include concepts from U.S.Pat. Nos. 6,757,587, 7,680,300, 8,301,421, 8,408,918, 8,428,781,9,357,708, U.S. Publication No. 2015/0199458, U.S. Publication No.2016/0321381, and U. S. Publication No. 2018/0060459, the entirecontents of each are incorporated herein by reference in their entirety.

Referring now to FIG. 1, an embodiment of a robotic system 100 for usein generation of one or more welding paths is provided. System 100 mayinclude a plurality of components, portions of which may be designed fora particular application and/or task. The first component of the systemmay include a software system 102 for adding new processes to a database104. Once built, database 104 may be reused by operators in the field orremotely. Operators may select an element from the database 104 using agraphical user interface 106 for execution by the control software 108as is shown in FIG. 1. Procedures for the particular application and/ortask (e.g. welding, robotic assembly, etc.) may be added to database 104by experts offline. This database 104 may be used with a graphical userinterface 106 and tasking software online to develop each procedure foreach task. The software modules may include, but are not limited totraining, tasking, and performance of the particular task, etc. All ofthis may be used to control the manner of operation of robotic hardware110. Robotic hardware 110 may respond to the controls received fromcontrol software 108 and may include one or more sensing devices,scanners, and/or other various devices as is discussed in further detailhereinbelow.

In a robotic system, the phrase “degrees of freedom” may refer tospecific, defined modes in which a mechanical device or system can move.The number of degrees of freedom may be equal to the total number ofindependent displacements or aspects of motion. For example, a sixdegrees of freedom (“6DOF”) scenario may refer to the freedom ofmovement of a rigid body in three-dimensional space. Specifically, thebody may be free to change position as forward/backward (surge), up/down(heave), left/right (sway) translation in three perpendicular axes,combined with changes in orientation through rotation about threeperpendicular axes, often termed yaw (normal axis), pitch (transverseaxis), and roll (longitudinal axis). In contrast, placing a point inspace may correspond three degrees of freedom, specifying a distancebetween two points on different links is one degree of freedom, etc.

In some embodiments, the phrase “robotic system”, as used herein, mayinclude a system of one, two, and/or any number of robots. In this way,an entire robotic system DOF may refer to the sum of the DOFs on each ofthe individual robots. This may include one DOF for each single-axisjoint, and six DOF for a free-moving base. For example, for a roboticsystem that includes two robots, one having 6DOF and the other having5DOF, the available entire robotic system degrees of freedom may be11DOF.

For example, and referring now to FIG. 2, a 3D rendering from agraphical user interface 200 depicting a welding tool having fivedegrees of freedom contrasted with a welding tool having six degrees offreedom, full 3D rotation and orientation, is provided. The differencebetween the two is the five degrees of freedom may be found by relaxingrotation about one axis. This particular model was tuned to optimize ascan and weld process. This involved configuring the bounding volumesaround the scanner tool, as well as aligning the system and base primaryframes to make the tool paths and point clouds appear in the correctlocations. The tool offsets were also configured based on how the toolpaths were created from the point clouds. The paths were created alongthe bottom of the seams, so an offset from the tip was configured sothere were no collisions. As shown in FIG. 2, the arm may be constrainedusing two different constraint sets, with each one using a differenttool offset, one for scanning the part and one for welding. The degreesof freedom set for scanning uses a six degree of freedom frame, and thewelding set uses a five degree of freedom frame that allows the tip ofthe torch to freely rotate around the tip. This allows scanning for thepart first, then relaxing of the degrees of freedom for the weld paths,which are more difficult for the robot to achieve given its workspaceenvelope.

In some embodiments, and referring now to FIG. 3, an embodimentdepicting a flowchart having a number of operations consistent with aweld path generation process is provided. As will be discussed infurther detail below, weld path generation process 10 may includescanning a welding area and generating 302 point cloud data. The processmay further include converting 304 the point cloud data to a heightfield and applying 306 a local minimum filter. The process may alsoinclude performing 308 binary image thinning and branch removal. Theestablished height field may be converted 310 back to a threedimensional space prior to simulation 312.

In some embodiments, and referring now to FIG. 4, another embodimentconsistent with a weld path generation process is provided. The methodmay include providing 402 one or more robots or robotic systems andscanning 404 a welding area using one or more three dimensional sensordevices associated with the one or more robots to generate a scannedwelding area. The system may include a processor configured to receive406 the scanned welding area and to generate 408 a three dimensionalpoint cloud based upon, at least in part the scanned welding area. Theprocessor may be further configured to perform processing 410 on thethree dimensional point cloud in a two-dimensional domain. The processormay be further configured to generate one or more three dimensionalwelding paths and to simulate 412 the one or more three dimensionalwelding paths.

Referring now to FIG. 5, a diagram 500 showing an embodiment consistentwith weld path generation process is provided. Diagram 500 depicts anexample of laser scanning and subsequent weld path generation. In someembodiments, a laser line scanner 502 may be used to pre-scan thewelding area. In this particular example, scanner 502 may be mounted tothe end of a robotic system. Weld path generation process may calculatethe weld path and volume and provide that information as an input to theon-line process as is discussed below. The right portion of diagram 500shows the resulting point cloud 504 that may be generated using thisparticular approach, here, having a resolution of 0.2 mm.

Referring now to FIG. 6, an example of a scanning system 600 that may beused in accordance with weld path generation process is provided. Forexample, a laser line scanner may be used for both pre-scanning thewelding area and also for on-line weld groove tracking. The laser linescanner may be mounted on the end effector of the robot and may bepositioned to look a few centimeters ahead of the welding area to avoidthe any light. It may be used to correct any weld path deviation awayfrom the pre-scanned data.

As shown in FIG. 6, laser line scanner 602 may be configured to operatein conjunction with a TIG torch 604 and rod feeder 606. This scanningsystem is provided merely by way of example as numerous scanners may beused in accordance with weld path generation process. For example,either two dimensional visible sensor or thermal sensors may be used tomonitor the welding process. As such, the visible sensor may be used torecord the entire process. The thermal information can be used toprevent overheating of the surrounding area. One related aspect of TIGwelding involves keeping the filler rod in the puddle. This may bemonitored using a conductivity sensor to sense the conductivity betweenthe filler rod and the metal. When the filler rod is in the puddle, therod and the metal are conducted, otherwise it is an open loop. Toprevent over feeding the filler rod, the feeding force may be monitored.If the filler rod was fed too quickly, it may hit the metal and theforce may increase. By monitoring the feeding force via a force sensorand the conductivity between the filler rod and the metal, the fillerrod can be maintained in the puddle.

In some embodiments, scanner 502, 602 may be configured to pre-scan thearea and find the weld path for offline planning and seam tracking foruse in an online process. During the pre-scanning process, the robot orrobotic system may be used to move the laser scanner linearly andcollect points for the point cloud. The resolution of the scanning maybe user specified and in this case, a 0.25 mm spacing was used.

In some embodiments, weld path generation process may be configured tocreate a weld path from the point cloud. For example, the point cloudmay be converted to a height field. Then points that are local minimumsmay be identified. This may be followed by a thinning process and branchremoval so the path becomes well defined. The point on the path may beused to calculate a path with normal and tangent defined.

Referring now to FIG. 7, an example showing a conversion from a threedimensional point cloud to a height field is provided. In thisparticular example, converting from the point cloud to the height fieldmay be fairly efficient. The point cloud may be converted to a twodimensional array with the height as the value in the entries of thearray. In this case the resolution of the grids may be 0.5 mm and,accordingly, the resulting array size is 506×451. This approach may workwell for most cases if the weld path is visible from one side. The datais essentially converted into a two dimensional image and sent to animage processing tool. In situations where the weld path may not bevisible from one side, such as welding to join two pipes, a differentscanning pattern may be needed.

Referring now to FIG. 8, an example showing a local minimum filter beingapplied to the height field two dimensional array is provided. Theresult is shown as a binary image. As discussed above, and in order toidentify the seam in the scanned data, a local minimum filter may beapplied. Given the kernel size k, number of angles and threshold t, thefilter may traverse through all of the points on the two dimensionalarray to see if the height difference from the center of the kernel tothe edge exceeds the threshold. FIGS. 8-9 show an example with k=10,number of angle=8 and threshold=1.25 mm. It can be seen that this is afairly effective filter to select the local minimum from scanned data.The only drawback is that the resulting weld path is relatively thick.

In some embodiments, weld path generation process may utilize binaryimage thinning techniques for reducing the thickness of a region withoutchanging the length. In contrast, image erosion, or dilation may end upchanging the width and length at the same time. In this particularexample, the end result of the thinning process provides regions of theimage having a width of one pixel. As can be seen from FIG. 10, theresulting image blocks may not be ready to be used as welding paths,there are branches in the region that need to be removed.

In some embodiments, and with regard to branch removal, the goal is tohave each image block include two leaf nodes and no branch node. As usedherein, a leaf node is referred to as a pixel that has only oneneighbor. A branch node is referred to as a pixel having more than twoneighbors. The branch removal process may include, but is not limitedto, creating a neighbor map, which registers each pixel with a codeindicating the presence of the 8 neighbors. This also creates a list ofthe leaf nodes and a list of the branch nodes. The branch removalprocess may then traverse through all leaf nodes, removing branches thatare shorter than a predefined threshold. The branch removal processfurther includes updating the neighbor map and visiting all of thebranch nodes and removing the ones that do not affect connectivity. Theprocess may then apply the thinning methodology and proceed back to thecreation of the neighbor map operation until the image stops changing.

Referring again to FIG. 10, an example of the branch removal process isprovided. In this case, branch nodes are color coded as blue, whichindicates that this pixel has more than two neighbors. Branch pixels arecolor coded as green and will be removed. Finally, the path created onthe height field may be converted back to the 3D space and displayedside by side with the original point cloud as shown in FIG. 11.

In some embodiments, after the branch removal process, each image blockmay now have exactly two leaf nodes and no branch node. It is possibleto connect the pixels in the block from one leaf nodes to the otherwithout any ambiguity. Additional information such as the normaldirection of the weld as well as the tangential direction of the pathmay be needed for orienting the weld head. In some cases it may bedesirable to position the weld head normal to the surface and alignedwith the tangential direction of the path. The tangential direction maybe calculated as

$\begin{matrix}{{v_{t}\left( p_{i} \right)} = \frac{\left( {p_{i + k} - p_{i - k}} \right)}{\left( {p_{i + k} - p_{i - k}} \right)}} & (1)\end{matrix}$

Where p_(i) is the i-th point of the path. The filter size k helps tosmooth the otherwise noisy tangent calculation. The normal vector maythen be calculated as

$\begin{matrix}{{{v_{t}\left( p_{i} \right)}}{v_{n} = \frac{\left( p_{i} \right)}{{\left( p_{i} \right)}}}} & (2)\end{matrix}$

Where v_(up) is the up direction unit vector. FIG. 12 shows an exampleof a conversion from three dimensional points to the path. Normal andtangential information may be added for orientation of the weld head. Inthis example of the converted path, blue indicates the normal and redindicating the tangent.

In some embodiments, weld path generation process may utilize one ormore graphical user interfaces to allow for user control of the process.For example, if jitter is identified in the weld path, the process mayallow for the application of a moving average filter and correspondinggraphical user interface for smoothing the path. By applying a movingaverage filter of size 7, it can be seen that the path was a lotsmoother after filtering. In the example shown in FIG. 16, a user mayspecify the filter size, start processing the point cloud, display theresult, then save the path to a file.

In some embodiments, weld path generation process may be configured touse one or more extra degrees of freedom to help control the weld poolformation relative to the gravity. In this, the focus is on the partsbeing hold by the robot. For example, one robot/mechanism may beconfigured to hold the weld head while another holds the part.Accordingly, the combined motion may allow for the weld head to movealong the weld path and/or maintain the weld pool formation against thedirection of the gravity.

It should be noted that although many of the embodiments included hereinare directed towards generating the weld path, with data obtained fromscanning prior to the welding other operations are also possible withoutdeparting from the scope of the present disclosure. For example, theextra degrees of freedom for helping against gravity may be used duringthe welding process. In some embodiments, this may be determined duringthe planning, for example, before the welding as well. Accordingly,embodiments of weld path generation process may use one or moreprocessors to maintain a welding formation with respect to gravity as awelding process is being performed. Maintaining the welding formationmay be based upon, at least in part, one or more extra degrees offreedom associated with the robot.

Additionally and/or alternatively, additional sensors and a laserscanner used for visual serving (e.g., fine turning the path inanticipating that the path can deviate from the planned path due toenvironment changes) may be used as well.

As will be appreciated by one skilled in the art, aspects of the presentdisclosure may be embodied as a system, method or computer programproduct. Accordingly, aspects of the present disclosure may take theform of an entirely hardware embodiment, an entirely software embodiment(including firmware, resident software, micro-code, etc.) or anembodiment combining software and hardware aspects that may allgenerally be referred to herein as a circuit,” “module” or “system.”Furthermore, aspects of the present disclosure may take the orm of acomputer program product embodied in one or more computer readablemedium(s) aving computer readable program code embodied thereon.

Any combination of one or more computer readable medium(s) may beutilized. The computer readable medium may be a computer readable signalmedium or a computer readable storage medium. A computer readablestorage medium may be, for example, but not limited to, an electronic,magnetic, optical, electromagnetic, infrared, or semiconductor system,apparatus, or device, or any suitable combination of the foregoing. Morespecific examples (a nonexhaustive list) of the computer readablestorage medium would include the following: an electrical connectionhaving one or more wires, a portable computer diskette, a hard disk, arandom access memory (RAM), a read-only memory (ROM), an erasableprogrammable readonly memory (EPROM or Flash memory), an optical fiber,a portable compact disc read-only memory (CD-ROM), an optical storagedevice, a magnetic storage device, or any suitable combination of theforegoing. In the context of this document, a computer readable storagemedium may be any tangible medium that can contain, or store a programfor use by or in connection with an instruction execution system,apparatus, or device.

A computer readable signal medium may include a propagated data signalwith computer readable program code embodied therein, for example, inbaseband or as part of a carrier wave.

Such a propagated signal may take any of a variety of forms, including,but not limited to, electro-magnetic, optical, or any suitablecombination thereof. A computer readable signal medium may be anycomputer readable medium that is not a computer readable storage mediumand that can communicate, propagate, or transport a program for use byor in connection with an instruction execution system, apparatus, ordevice. Program code embodied on a computer readable medium may betransmitted using any appropriate medium, including but not limited towireless, wireline, optical fiber cable, RF, etc., or any suitablecombination of the foregoing.

Computer program code for carrying out operations for aspects of thepresent disclosure may be written in any combination of one or moreprogramming languages, including an object oriented programming languagesuch as Smalltalk, C++ or the like and conventional proceduralprogramming languages, such as the “C” programming language or similarprogramming languages. The program code may execute entirely on theuser's computer, partly on the user's computer, as a stand-alonesoftware package, partly on the user's computer and partly on a remotecomputer or entirely on the remote computer or server. In the latterscenario, the remote computer may be connected to the user's computerthrough any type of network, including a local area network (LAN) or awide area network (WAN), or the connection may be made to an externalcomputer (for example, through the Internet using an Internet ServiceProvider).

Aspects of the present disclosure are described below with reference toflowchart illustrations and/or block diagrams of methods, apparatus(systems) and computer program products according to embodiments of thedisclosure. It will be understood that each block of the flowchartillustrations and/or block diagrams, and combinations of blocks in theflowchart illustrations and/or block diagrams, can be implemented bycomputer program instructions. These computer program instructions maybe provided to a processor of a general purpose computer, specialpurpose computer, or other programmable data processing apparatus toproduce a machine, such that the instructions, which execute via theprocessor of the computer or other programmable data processingapparatus, create means for implementing the functions/acts specified inthe flowchart and/or block diagram block or blocks.

These computer program instructions may also be stored in a computerreadable medium that can direct a computer, other programmable dataprocessing apparatus, or other devices to function in a particularmanner, such that the instructions stored in the computer readablemedium produce an article of manufacture including instructions whichimplement the function/act specified in the flowchart and/or blockdiagram block or blocks.

The computer program instructions may also be loaded onto a computer,other programmable data processing apparatus, or other devices to causea series of operational steps to be performed on the computer, otherprogrammable apparatus or other devices to produce a computerimplemented process such that the instructions which execute on thecomputer or other programmable apparatus provide processes forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks.

The flowchart and block diagrams in the Figures illustrate thearchitecture, functionality, and operation of possible implementationsof systems, methods and computer program products according to variousembodiments of the present disclosure. In this regard, each block in theflowchart or block diagrams may, but not always, represent a module,segment, or portion of code, which comprises one or more executableinstructions for implementing the specified logical function(s). Itshould also be noted that, in some alternative implementations, thefunctions noted in the block may occur out of the order noted in thefigures. For example, two blocks shown in succession may, in fact, beexecuted substantially concurrently, or the blocks may sometimes beexecuted in the reverse order, depending upon the functionalityinvolved. It will also be noted that each block of the block diagramsand/or flowchart illustration, and combinations of blocks in the blockdiagrams and/or flowchart illustration, can be implemented by specialpurpose hardware-based systems that perform the specified functions oracts, or combinations of special purpose hardware and computerinstructions.

The terminology used herein is for the purpose of describing particularimplementations only and is not intended to be limiting of thedisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps (notnecessarily in a particular order), operations, elements, and/orcomponents, but do not preclude the presence or addition of one or moreother features, integers, steps (not necessarily in a particular order),operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements that may be in the claims below areintended to include any structure, material, or act for performing thefunction in combination with other claimed elements as specificallyclaimed. The description of the present disclosure has been presentedfor purposes of illustration and description, but is not intended to beexhaustive or limited to the disclosure in the form disclosed. Manymodifications, variations, substitutions, and any combinations thereofwill be apparent to those of ordinary skill in the art without departingfrom the scope and spirit of the disclosure. The implementation(s) werechosen and described in order to best explain the principles of thedisclosure and the practical application, and to enable others ofordinary skill in the art to understand the disclosure for variousimplementation(s) with various modifications and/or any combinations ofimplementation(s) as are suited to the particular use contemplated.

Having thus described the disclosure of the present application indetail and by reference to implementation(s) thereof, it will beapparent that modifications, variations, and any combinations ofimplementation(s) (including any modifications, variations,substitutions, and combinations thereof) are possible without departingfrom the scope of the disclosure defined in the appended claims.

What is claimed is:
 1. A system comprising: a robot; one or more threedimensional sensor devices associated with the robot configured to scana welding area and generate a scanned welding area; and one or moreprocessors configured to receive the scanned welding area and togenerate a three dimensional point cloud based upon, at least in partthe scanned welding area, the one or more processors further configuredto perform processing on the three dimensional point cloud in atwo-dimensional domain, the one or more processors further configured togenerate one or more three dimensional welding paths and to simulate theone or more three dimensional welding paths.
 2. The system of claim 1,wherein processing the three-dimensional point cloud in atwo-dimensional domain includes at least one of binary image thinning ofa welding path or smoothing a welding path based upon, at least in part,a moving average filter.
 3. The system of claim 1, wherein processingthe three-dimensional point cloud in a two-dimensional domain includesanalysis of one or more environmental or robot constraints.
 4. Thesystem of claim 1, wherein simulating the one or more three dimensionalwelding paths includes verifying feasibility of the one or more threedimensional welding paths.
 5. The system of claim 4, wherein if the oneor more three dimensional welding paths are not verified, the one ormore processors further configured to re-simulate after altering aposition of a welding table or a welding part.
 6. The system of claim 1,wherein performing processing on the three dimensional point cloud in atwo-dimensional domain includes converting the three dimensional pointcloud to a height field.
 7. The system of claim 6, wherein performingprocessing on the three dimensional point cloud in a two-dimensionaldomain includes applying a local minimum filter to the height field. 8.The system of claim 2, wherein binary image thinning includes removingone or more branch nodes, wherein a branch node corresponds to a pixelhaving more than two neighbors.
 9. The system of claim 1, furthercomprising: displaying a graphical user interface configured to allow auser to select a filter size, select a point cloud for processing,visualize a weld path result or save the one or more three-dimensionalwelding paths.
 10. The system of claim 1, wherein the one or moreprocessors are configured to use one or more extra degrees of freedom tomaintain a welding formation with respect to gravity as a weldingprocess is being performed.
 11. A method comprising: providing a robot;scanning a welding area using one or more three dimensional sensordevices associated with the robot to generate a scanned welding area;receiving the scanned welding area at one or more processors; generatinga three dimensional point cloud based upon, at least in part the scannedwelding area; processing the three dimensional point cloud in atwo-dimensional domain to generate one or more three dimensional weldingpaths; and simulating the one or more three dimensional welding paths.12. The method of claim 11, wherein processing the three-dimensionalpoint cloud in a two-dimensional domain includes at least one of binaryimage thinning of a welding path or smoothing a welding path based upon,at least in part, a moving average filter.
 13. The method of claim 11,wherein processing the three-dimensional point cloud in atwo-dimensional domain includes analysis of one or more environmental orrobot constraints.
 14. The method of claim 11, wherein simulating theone or more three dimensional welding paths includes verifyingfeasibility of the one or more three dimensional welding paths.
 15. Themethod of claim 14, wherein if the one or more three dimensional weldingpaths are not verified, the one or more processors further configured tore-simulate after altering a position of a welding table or a weldingpart.
 16. The method of claim 11, wherein performing processing on thethree dimensional point cloud in a two-dimensional domain includesconverting the three dimensional point cloud to a height field.
 17. Themethod of claim 16, wherein performing processing on the threedimensional point cloud in a two-dimensional domain includes applying alocal minimum filter to the height field.
 18. The method of claim 12,wherein binary image thinning includes removing one or more branchnodes, wherein a branch node corresponds to a pixel having more than twoneighbors.
 19. The method of claim 11, further comprising: displaying agraphical user interface configured to allow a user to select a filtersize, select a point cloud for processing, visualize a weld path resultor save the one or more three-dimensional welding paths.
 20. The methodof claim 11, further comprising: using one or more processors tomaintain a welding formation with respect to gravity as a weldingprocess is being performed wherein maintaining the welding formation isbased upon, at least in part, one or more extra degrees of freedomassociated with the robot.